Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011) Installation guide

Brand: Maxon

Model: RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011)

Category: Welding System

Type: Installation guide

Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011)

This manual provides instructions for installing the Maxon liftgate models RC-2B, RC-3B, RC-4B, RC-5B, RC-6B, and RC-6K, with capacities ranging from 2000 to 6000 pounds. These liftgates are designed for installation on flatbed trucks and trailers, and are capable of lifting and lowering heavy loads.

The liftgates feature a variety of options and accessories, including:

Hydraulic or cam-operated closing mechanisms
Hand pump option for cam closer
Battery pack installation for trailers
Fixed or hinged ramps
Cart stops and dual cart stop ramps

Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011)

The liftgates feature a variety of options and accessories, including:

Hydraulic or cam-operated closing mechanisms
Hand pump option for cam closer
Battery pack installation for trailers
Fixed or hinged ramps
Cart stops and dual cart stop ramps

11921 Slauson Avenue.

Santa Fe Springs, CA. 90670

(800) 227-4116

INSTALLATION

MANUAL

RC-2B

RC-3B

RC-4B

RC-5B

RC-6B

RC-6K

M-90-1

REV. G

NOVEMBER 2011

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

TABLE OF CONTENTS

WARNINGS ........................................................................................................................... 3

SAFETY INSTRUCTIONS .................................................................................................... 3

INTRODUCTION ...................................................................................................................4

UNIT AS SHIPPED ................................................................................................................5

INSTALLATION OF UNIT ...................................................................................................... 6

WELDING TO FLATBED ......................................................................................................11

HYDRAULIC PIPE INSTALLATION .................................................................................... 12

POWER PACK INSTALLATION .......................................................................................... 13

FUSED POWER CABLE ..................................................................................................... 16

PUMP WIRING CAM CLOSER ........................................................................................... 17

PUMP WIRING HYDRAULIC CLOSER .............................................................................. 18

ADD HYDRAULIC FLUID .................................................................................................... 19

FINAL ADJUSTMENTS ....................................................................................................... 21

ATTACH DECALS ............................................................................................................... 23

OPTIONS ............................................................................................................................ 25

RCT LIGHT INSTALLATION ................................................................................................ 25

RCT LIGHT INSTALLATION - Continued ............................................................................ 26

HAND PUMP OPTION FOR CAM CLOSER ....................................................................... 27

BATTERY PAK INSTALLATION (For Trailers) ..................................................................... 28

RECOMMENDED LIFTGATE POWER CONFIGURATION ................................................ 29

BATTERY CABLE MOUNTING, 6 VOLT SYSTEM ............................................................. 31

BATTERY CABLE MOUNTING, 12 VOLT SYSTEM ........................................................... 32

FIXED RAMP INSTALLATION, 6” ....................................................................................... 33

FIXED RAMP INSTALLATION, 12” ..................................................................................... 34

CART STOP & DUAL CART STOP RAMP INSTALLATION ................................................ 35

HINGED RAMP INSTALLATION (STEEL) .......................................................................... 36

HINGED RAMP INSTALLATION (ALUMINUM) ................................................................... 37

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

SAFETY INSTRUCTIONS

WARNINGS

SAFETY INSTRUCTIONS

 Comply with all WARNING and instruction decals attached to the Liftgate.

 Keep decals clean and legible. If decals are illegible or missing, replace them. Free replacement

decals are available from Maxon Customer Service.

 Consider the safety and location of bystanders and location of nearby objects when operating the

Liftgate. Stand to one side of the platform while operating the Liftgate

 Do not stand, or allow obstructions, under the platform when lowering the Liftgate. Be sure your

feet are clear of the Liftgate.





 Wear appropriate safety equipment such as protective eyeglasses, faceshield and clothing while

performing maintenance on the Liftgate and handling the battery. Debris from drilling and contact

with battery acid may injure unprotected eyes and skin.

 while installing Liftgate. Connect vehicle

battery power to the Liftgate only when installation is complete or as required in the installation

instructions.

 Do not allow untrained persons to operate the Liftgate.







skin, immediately wash it off with soap and water.

-

trol switch to stop the Liftgate.





 Read and understand the instructions in this Installation Manual before installing Liftgate.

 Before operating the Liftgate, read and understand the operating instructions in 

Manual.



during operation comes from the power unit while the platform is raised and lowered. Listen for

scraping, grating and binding noises and correct the problem before continuing to operate Liftgate.



objects clear of the inboard edge of the platform. Your feet or objects on the platform can become

trapped between the platform and the Liftgate extension plate.









WARNING



. Damage to Liftgate and/or vehicle, and

personal injury can result from welds that are done incorrectly.

WARNINGS

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

INTRODUCTION

This publication contains the information required to install the following

models and their options; , and RCHL from 2000

to 6000 pound capacities. If there is any doubt in your mind regarding the

suitability of these lifts being installed on its intended vehicle, or any portion

of these instructions that you do not understand, please contact the Maxon

Customer Service Department for consultation.

 



installation. These kinds of changes should be discussed with our Engineering

Department before being undertaken.

Bed height requirements to ground are 38” laden to 56” unladen.

These lifts cannot be installed on bodies with swing type doors.

 

wide, in the case of the RCW Models). If this body has dimensions that are

much different than these, special brackets will have to be fabricated for

attachment. The corner posts of the body must also be made of steel so that

the lift columns can be welded to it. If they are aluminum, then steel plates

will have to be fabricated to bolt to these corner posts for welding to the lift

assembly. Both of the above conditions are rare and therefore have not been

provided for in this manual. Contact the Customer Service Department if either

of the above conditions exist.

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

UNIT AS SHIPPED

Do not remove stands at bottom of column until instructed to do so.

Steel box containing pump assembly, also contains a packing

list, instruction manuals, decals, and all necessary hardware

to complete installation.

COLUMN SUPPORT ANGLES 48”

POWER UNIT BOX

REINFORCEMENT ANGLE 8”

Two of these 18” angle iron pieces are



the lift to the truck, and then to support

the pump box on trailer installations.

The other two are welded to the column

support angles.

STAND

BATTERY



PUMP BOX

STAND

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

INSTALLATION OF UNIT

There are two pieces of angle iron supports (2-1/2 x 2-1/2 x

18”) that have been provided to assist in lining the unit up to the

body. Tack weld them to the top of the lifts main section, just



and ready to weld. Put a chalk mark on the center of the unit (on

the thread plate surface) for aligning with the center of the truck

body.

Remove support angles after lift is mounted and use them for

pump box mount reinforcement.

SUPPORT ANGLE

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713





body.



with the mark on the liftgate.

Using the lifting straps, the unit can now be raised either with a chain hoist or

fork lift to a height which will allow the temporary support angles to rest on the



they meet.



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

Clamp columns to the truck body and weld

as shown. Remove forklift or chain hoist.



1/4” Fillet Weld. 2” Long



1/4” Fillet Weld. 3” Long



1/4” Fillet Weld. 4” Long

NOTE: See views A & B on next page.

ALL UNITS:

approx. halfway

down the column.

ALL UNITS: See view C on

the next page.



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

DO NOT WELD COVER

COVER



TYP.

WELD TO CORNER

POST AND SILL



OUTSIDE OF COLUMN ASSEMBLY

INSIDE OF COLUMN ASSEMBLY



(Length as



on previous

page.)



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

Cut columns off 20” from ground. Place the 2-1/2” x 18”

angle iron provided under at least 2 cross members, to

prepare for the following step and weld.

Cut one end of each of the 4 foot long angle iron braces

so that it lines up with the lift column and the other end



paragraph.

20”

LIFT COLUMN

CUT

STAND

OFF



ANGLE

WELD



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

WELDING TO FLATBED

The column assemblies are



with two lengths of channel. The





3”-4.1 #/ft. Channel



4”-5.4 #/ft. Channel

NOTE: Mounting Channel is not supplied by Maxon









If side rail is less than 1/4” thick,

weld a 1/4” plate to side rail, then

weld channel to 1/4” plate.









Weld to side rail

above a cross

member.





Cross Member

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

HYDRAULIC PIPE INSTALLATION

Remove the seven foot long pipe that is strapped to this column of the

lift gate (two pipes if lift has hydraulic platform closer), and weld to under



the truck body. Connect the four foot hoses to the end of the pipe(s) closest

to the power unit and the other end through the pump box to the pump

assembly. See the last page of “Power Pak Installation” for details.

NOTE: Blow air through pipes and hoses before connections are made.



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713





TRAILER BODIES

Jack up the steel box containing the pump assembly until it touches at least



touches the truck chassis frame. Weld where instructed and remove jack.

Leave room for tail lights.

WELD

MAX.

Jack up the steel box containing the pump assembly until it touches





members. Weld both ends of braces and top of box. Use short pieces of angle



the box.

Make sure the box is not in a position to interfere with the wheels of the

trailer with sliding axle.

Box can also be placed behind the wheels if room permits.





BRACE

FLOOR CROSS

MEMBERS

WELD ALL

SIDES OF

ANGLE

POWER UNIT BOX





11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

Run 32 ft. power cable from the pump box, along the chassis frame to the

positive terminal of the battery (assuming the negative is ground). Use frame

clips to secure the cable. (Do not attach to the battery terminal until the other

end is fastened on the pump). If the cable is too long, cut to proper length.



TERMINAL





POWER

CABLE

Strip about 1/2” of the insulation from the end and slide one of the

pieces of shrink tube far enough down that it’s out of your way. Solder the



Always wear protective eye covering while you are doing soldering

operations.

When it’s cool, slide the shrink tube over the terminal end and heat with

a heat gun til it shrinks tightly over the cable and terminal.

NOTE:

Proper cable connections are extremely important to insure a long and



solder and shrink tubing are provided to insure proper connections. Please

do not use the hammer smashing method since the constant bouncing and

vibration of the vehicle can eventually cause these types of joints to loosen

and deteriorate.

 

tool is used.

POWER

CABLE

FRAME

CLIP



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

Route the two hoses (3 if hydraulic closer) and the three conductor cord

(two cords if hydraulic closer), that come out of the bottom of the lift gate main

frame through the power pak box and connect as shown.



TRAILERS ONLY

Connect hydraulic hose coming out of bottom of lift gate to

welded pipes under body. Tie the cord(s) and the low pressure line

to the pipe and route through power unit box.



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

FUSED POWER CABLE



DESCRIPTION PART NUMBER FIGURE









ASSEMBLY



Do not attach cable to battery until Liftgate is



WARNING















SHORT END TO

VEHICLE BATTERY

LONG END TO

MOTOR SOLENOID

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

PUMP WIRING CAM CLOSER

POWER TO

WHT.



DOWN

TOGGLE

SWITCH









WHT

GRN

GND



11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

PUMP WIRING HYDRAULIC CLOSER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713

DECAL



ADD HYDRAULIC FLUID

3..

4. When Liftgate is ready to operate,

unfold and lower the platform to

ground level. (See 

Manual.)

 







FILLER

CAP

2.

. Add 4



to reservoir. (Refer to the

NOTE above.)

CAUTION













NOTE:

See  for recommended brands.

 Open pump box cover .

5..



of the GRAVITY DOWN bar on the

decal. If necessary,



NOTE: To check oil level in the pump

reservoir, platform must be at

ground level.

.

PUMP BOX WITH OPEN COVER



PUMP BOX

COVER

11921 Slauson Ave. Santa Fe Springs, CA. 90670 (800) 227-4116 FAX (888) 771-7713





ISO 32 HYDRAULIC OIL

RECOMMENDED

BRANDS

PART NUMBER

AMSOIL AWH-05

CHEVRON HIPERSYN 32

KENDALL GOLDEN MV

SHELL TELLUS S2 V32

EXXON UNIVIS N-32

MOBIL

DTE-13M, DTE-24,

HYDRAULIC OIL-13

HYDRAULIC OIL

RECOMMENDED

BRANDS

PART NUMBER

AMSOIL AWF-05

CHEVRON FLUID A, AW-MV-15

KENDALL GLACIAL BLU

SHELL TELLUS S2 V15

EXXON UNIVIS HVI-13

MOBIL DTE-11M

ROSEMEAD THS FLUID 17111



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Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011) Installation guide

Brand: Maxon

Model: RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011)

Category: Welding System

Type: Installation guide

Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011)

The liftgates feature a variety of options and accessories, including:

Hydraulic or cam-operated closing mechanisms
Hand pump option for cam closer
Battery pack installation for trailers
Fixed or hinged ramps
Cart stops and dual cart stop ramps

Download PDF

report

Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011) Installation guide

Maxon RC-2B,RC-3B, RC-4B, RC-5B, RC-6B, RC-6K Series (November 2011) Installation guide

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